Multilayer and multifunctional woven fabrics and methods of making the same

ABSTRACT

A multilayer fabric includes at least a first woven fabric layer and a second woven fabric layer tacked to the first woven fabric layer. The first woven fabric layer provides a first functionality to the multilayer fabric, the second woven fabric layer provides a second functionality to the multilayer fabric, and the first functionality is different than the second functionality. A method for forming a multilayer fabric includes weaving a first fabric layer on a loom, the first fabric layer having a first functionality, weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different than the first functionality, and tacking the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom. The multilayer fabric may include multiple fabric layers, such as from 2 to 8 fabric layers.

RELATED APPLICATION

The present disclosure claims the benefit of U.S. Provisional Patent Application No. 62/570,902, filed Oct. 11, 2017, entitled “Multilayer and multifunctional woven fabrics and methods of making the same,” the contents of which are incorporated herein by this reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to multilayer woven fabrics, and in particular to multilayer and multifunctional woven fabrics with each layer providing a different functionality to the woven fabric.

BACKGROUND OF THE DISCLOSURE

Dual layer fabrics are available in the garment market in various forms. In one form, two or more separately woven or knitted fabrics are combined together using either lamination bonding or by stitching/sewing the fabrics together. Another form is a two-layer fleece fabric. Though the garments made from these types of construction can provide certain functionalities like warming, wind proofing, etc., they also have various deficiencies. For example, the fabrics are bulky, the processes of making the fabrics are expensive and inefficient, the fabrics lack breathability (especially in lamination constructions that include a film such as polytetrafluoroethylene), and the aesthetics of the fabrics may be compromised.

These and other shortcomings are addressed by aspects of the present disclosure.

SUMMARY

Aspects of the disclosure relate to a multilayer fabric including at least a first woven fabric layer and a second woven fabric layer tacked to the first woven fabric layer. The first woven fabric layer provides a first functionality to the multilayer fabric, the second woven fabric layer provides a second functionality to the multilayer fabric, and the first functionality is different than the second functionality. The multilayer fabric may include multiple fabric layers, such as from 2 to 8 fabric layers.

Aspects of the disclosure further relate to methods for forming a multilayer fabric including: weaving a first fabric layer on a loom, the first fabric layer having a first functionality; weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different than the first functionality; and tacking the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom. The multilayer fabric may include multiple fabric layers, such as from 2 to 8 fabric layers.

BRIEF DESCRIPTION OF THE FIGURES

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

FIG. 1 is an illustration of a multilayer fabric according to an aspect of the disclosure.

FIGS. 2A-2C are annotated photographs of multilayer fabrics according to aspects of the disclosure.

FIG. 3 is a flowchart illustrating a method for making a multilayer fabric according to an aspect of the disclosure.

FIG. 4 is an illustration of a multilayer fabric according to an aspect of the disclosure.

FIGS. 5A-C are illustrations of 2-layer multilayer fabrics according to further aspects of the disclosure.

FIGS. 6A and 6B are illustrations of 3-layer and 4-layer multilayer fabrics according to aspects of the disclosure.

FIGS. 7A and 7B are illustrations of a prior art fleece fabric (FIG. 7A) and a multilayer (2-layer) denim fabric according to an aspect of the disclosure (FIG. 7B).

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description of the disclosure and the Examples included therein. In various aspects, the present disclosure pertains to a multilayer fabric including at least a first woven fabric layer and a second woven fabric layer tacked to the first woven fabric layer. The first woven fabric layer provides a first functionality to the multilayer fabric, the second woven fabric layer provides a second functionality to the multilayer fabric, and the first functionality is different than the second functionality.

Before the present compounds, compositions, articles, systems, devices, and/or methods are disclosed and described, it is to be understood that they are not limited to specific synthetic methods unless otherwise specified, or to particular reagents unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

Various combinations of elements of this disclosure are encompassed by this disclosure, e.g., combinations of elements from dependent claims that depend upon the same independent claim.

Moreover, it is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.

Definitions

It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” can include the embodiments “consisting of” and “consisting essentially of” Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined herein.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a fiber” includes mixtures of two or more fibers.

As used herein, the term “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like.

Ranges can be expressed herein as from one value (first value) to another value (second value). When such a range is expressed, the range includes in some aspects one or both of the first value and the second value. Similarly, when values are expressed as approximations, by use of the antecedent ‘about,’ it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

As used herein, the terms “about” and “at or about” mean that the amount or value in question can be the designated value, approximately the designated value, or about the same as the designated value. It is generally understood, as used herein, that it is the nominal value indicated ±10% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. It is understood that where “about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase “optional additional woven fabric layers” means that the additional woven fabric layer(s) can or cannot be included and that the disclosure includes multilayer fabrics that both include and that do not include additional woven fabric layer(s).

Unless otherwise stated to the contrary herein, all test standards are the most recent standard in effect at the time of filing this application.

Each of the materials disclosed herein are either commercially available and/or the methods for the production thereof are known to those of skill in the art.

It is understood that the compositions disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.

Multilayer Fabrics

With reference to FIG. 1, aspects of the disclosure relate to a multilayer fabric 100 including at least a first woven fabric layer 120 and a second woven fabric layer 140 tacked 160 to the first woven fabric layer 120. The first woven fabric layer 120 provides a first functionality (e.g., property, feature, characteristic or attribute) to the multilayer fabric 100, and the second woven fabric layer 140 provides a second functionality to the multilayer fabric 100. The first functionality is different than the second functionality.

The first functionality and the second functionality may be any desirable property, feature, characteristic or attribute of a fabric. In some aspects the first functionality and the second functionality are selected from one or more of warming, cooling, all season, flame resistance, antibacterial, odor control, retro-reflectivity, ultraviolet protection, friction resistance, wear resistance, energy resistance, water repellency, water proofing, wind resistance, moisture wicking, thermal conductivity, electrical conductivity, stretch, non-stretch, softness, hand, slub, fabric smoothness, yarn size, printability, dyeability, color, color changing, pattern changing, responsivity (e.g., yarns may be responsive such that properties, including but not limited to yarn color, yarn size, yarn twisting form can change as humidity, temperature and pH changes), energy boosting, skin-moisturizer, infrared (IR) transmitting, IR reflecting, IR absorbing, ventilation, controllable shrinkage, sensing properties, and aesthetic look or feel (for example, rough, smooth, silky, sticky, patterns, wet/humid, dry hand feel).

The first woven fabric layer 120 and the second woven fabric layer 140 may each include more than one functionality (which may overlap) and provide those functionalities to the multilayer fabric 100. If, for example, the first woven fabric layer 120 provides functionalities of flame resistance, water resistance and warmth, and the second woven fabric layer 140 provides functionalities of warmth and moisture wicking, then the collective functionality that the first woven fabric layer 120 provides to the multilayer fabric 100 is different than the collective functionality that the second woven fabric layer 140 provides to the multilayer fabric 100.

The first woven fabric layer 120 includes first yarns woven into a first fabric construction. The first fabric construction includes a first weave type, which can include a plain weave, a twill weave, a satin weave, a pile weave, a dobby weave, a knit-look weave (i.e., a weave that simulates the look of a knit fabric), a rip-stop, derivatives thereof, and combinations thereof. As used herein, a “derivative” of a weave is a variation in the traditional weave type for the above-mentioned weaves. For example, a traditional plain weave is a 1×1 weave. A 2×2 plain weave, or basket weave, may be considered a derivative of a plain weave. Similarly, a traditional twill weave repeats on three or more ends and picks of a fabric and produces a diagonal line on the face of the fabric. A twill derivative weave may be any twill weave that deviates from this pattern (e.g., a 4×1 twill, 5×1 twill, etc.).

The first yarns are woven into the first fabric construction in both a warp direction and a weft direction. The first yarns woven in the warp direction and the first yarns woven in the weft direction may include the same/identical yarn type (e.g., the same types of fibers in the yarns, the same form of the fibers, the same yarn size and the same color) or may have a different yarn type (e.g., the yarns in the warp and weft direction may have different fibers, a different form, a different yarn size, and/or a different color).

In some aspects the first functionality is provided by the first yarns, such as by the fibers selected for the first yarns, the form of the fibers (e.g., spun yarns or filament yarns), the yarn size, and/or the yarn color. In other aspects the first functionality is provided by the first fabric construction, such as by the selection of the first weave type. In further aspects the first functionality is provided by both the first yarns and the first fabric construction. In some aspects the first functionality is provided by the first yarns woven in the warp direction, by the first yarns woven in the weft direction, or by the first yarns woven in both the warp direction and in the weft direction.

The second woven fabric layer 140 includes second yarns woven into a second fabric construction. The second fabric construction includes a second weave type, which can include a plain weave, a twill weave, a satin weave, a pile weave, a dobby weave, a knit-look weave, a rip-stop, derivatives thereof, and combinations thereof.

The second yarns are woven into the second fabric construction in both a warp direction and a weft direction. The second yarns woven in the warp direction and the second yarns woven in the weft direction may include the same/identical yarn type (e.g., the same types of fibers in the yarns, the same form of the fibers, the same yarn size and the same color) or may have a different yarn type (e.g., the yarns in the warp and weft direction may have different fibers, a different form, a different yarn size, and/or a different color).

In some aspects the second functionality is provided by the second yarns, such as by the fibers selected for the second yarns, the form of the fibers (e.g., spun yarns or filament yarns), the yarn size, and/or the yarn color. In other aspect the second functionality is provided by the second fabric construction, such as by the selection of the second weave type. In further aspects the second functionality is provided by both the second yarns and the second fabric construction. In some aspects the second functionality is provided by the second yarns woven in the warp direction, by the second yarns woven in the weft direction, or by the second yarns woven in both the warp direction and in the weft direction.

The first yarns and the second yarns may be independently selected from spun yarns, filament yarns, fancy yarns, bi-component yarns, core sheath hybrid yarns, or a combination thereof. Core sheath hybrid yarns include a core of one or more filament yarns wrapped with a spun yarn sheath.

The spun yarns may include staple fibers including, but not limited to, cotton, flax, jute, hemp, ramie, bamboo, pineapple, banana, wool, bean, milk, cashmere, silk, kapok, polyester, nylon (including but not limited to nylon 6 and nylon 66), polypropylene, acrylic, rayon, cellulose, acetate, viscose, modal, lyocell, para aramid, meta aramid, polytetrafluoroethylene, FR cotton, FR polyester, FR nylon, polylactic acid (PLA), poly(trimethylene terephthalate) (PTT), polybenzimidazole (PBI), conductive fibers, optical fibers, copolymers thereof, blends thereof, and combinations thereof.

The filament yarns may include fibers including, but not limited to, polyester, nylon (including but not limited to nylon 6 and nylon 66), polyethylene, polypropylene, acrylic, cellulose-acetate, viscose, modal, lyocell, meta aramid, para aramid, polytetrafluoroethylene, FR polyester, FR nylon, melamine, modacrylic, elastomeric fibers (including but not limited to spandex), polylactic acid (PLA), poly(trimethylene terephthalate) (PTT), polybenzimidazole (PBI), conductive fibers, optical fibers, bi-component filament comprising two of these fibers, multi-component filament comprising three or more of these fibers, copolymers thereof, blends thereof, and combinations thereof. One exemplary bi-component fiber includes polyester and nylon, such as the AeroReact fibers available from Nike. Another exemplary bi-component fiber includes cellulose and acetate, such as the VENTCOOL™ fibers available from Mitsubishi Chemical. Fabrics formed from bi-component fibers, combined with appropriate fabric constructions, provide good moisture management, breathability and thermoregulating properties because the fibers expand when they get wet (such as from perspiration), allowing further moisture and heat from the body to exit. In addition, the fibers are quick-drying, and therefore rapidly shrink, providing good warmth to the wearer.

In a particular aspect the first yarns and the second yarns include spun yarns including cotton staple fibers, and the first weave type and the second weave type are both a twill weave. Twill woven fabrics formed of spun cotton yarns are commonly referred to as denim/workwear fabrics. Thus, certain aspects of the disclosure include multilayer denim/workwear fabrics having a denim/workwear first woven fabric layer 120 and a denim/workwear second woven fabric layer 140, but one or both of the denim/workwear fabric layers include other fibers so that the two fabric layers have different functionalities.

As noted, the second woven fabric layer 140 is tacked 160 to the first woven fabric layer 120. The second woven fabric layer 140 may be tacked 160 to the first woven fabric layer 120 in any suitable manner. In some aspects the second woven fabric layer 140 is tacked 160 to the first woven fabric layer 120 in the warp direction, the weft direction, or in both the warp direction and the weft direction. Tacking 160 of the second woven fabric layer 140 to the first woven fabric layer 120 creates air pockets between the first woven fabric layer 120 and the second woven fabric layer 140. The size and configuration of the air pockets may be adjusted based on the tacking pattern, as illustrated in FIGS. 2A-2C. In FIG. 2A, the second woven fabric layer 140 is closely tacked 160 to the first woven fabric layer 120 in both the warp direction and the weft direction so as to create small air pockets roughly in the shape of squares (see the dark lines provided for ease of reference). In FIG. 2B, the second woven fabric layer 140 is less closely tacked 160 to the first woven fabric layer 120 in both the warp direction and the weft direction so as to create larger air pockets roughly in the shape of squares (see the dark lines provided for ease of reference). In FIG. 2C, the second woven fabric layer 140 is widely tacked 160 to the first woven fabric layer 120 in only one direction (e.g., the warp direction) so as to create wide longitudinal air pockets (see the dark lines provided for ease of reference). In this manner the tacking can be performed in an pattern such that air pockets are formed in the multilayer fabric 100 in a pattern. While square and longitudinal air pockets are described an illustrated, it will be recognized that other air pocket configurations (e.g., rectangular, triangular, etc.) could be formed in the multilayer fabric 100 by using different tacking patterns. In this manner, the air pockets can be formed in the multilayer fabric 100 in a tunable patter with a tunable size.

In some aspects the air pockets provide thermal insulation to the multilayer fabric 100. In further aspects the air pockets provide other functionalities to the multilayer fabric 100. Purely by way of example, the air pockets could be filled with one or more materials, including but not limited to insulation (e.g., down insulation and synthetic insulation including but not limited to ThermoBall™ insulation from The North Face), fiberfill filler, aerogel fibers, and electronics (sensors, actuators and wires).

The first woven fabric layer 120 and the second woven fabric layer 140 of the multilayer fabric 100 may be simultaneously woven on the same loom. While in some aspects a multiple warp beam may be used to weave the first woven fabric layer 120 and the second woven fabric layer 140, in a particular aspect the first woven fabric layer 120 and the second woven fabric layer 140 are simultaneously woven using a single warp beam. In certain aspects the first woven fabric layer 120 and the second woven fabric layer 140 are simultaneously woven using double warp beams.

The multilayer fabric 100 may include more than two woven fabric layers, such as three, four or more than four woven fabric layers. The additional woven fabric layers may be tacked to one or both of the first woven fabric layer 120 and the second woven fabric layer 140. Thus, in some aspects the multilayer fabric 100 includes at least a third woven fabric layer tacked to one or both of the first woven fabric layer 120 and the second woven fabric layer 140. The third woven fabric layer has a third functionality different than one or both of the first functionality and the second functionality.

The multilayer fabric 100 can have any desirable fabric weight. In some aspects the fabric has a weight of from about 6 to about 16 ounces per square yard (osy). In certain aspects the multilayer fabric has a weight of from about 8 to about 14.5 osy.

Methods for Forming a Multilayer Fabric

Aspects of the disclosure further relate to methods for forming a multilayer fabric. With reference to FIG. 3, the method 300 includes, at step 320, weaving a first fabric layer 120 on a loom, the first fabric layer 120 having a first functionality. At step 340 a second fabric layer 140 is woven on the loom. The second fabric layer 140 has a second functionality different than the first functionality. At step 360 the second fabric layer 140 is tacked 160 to the first fabric layer 120 while the first fabric layer 120 and the second fabric layer 140 are on the loom. In some aspects the step 360 of tacking 160 the second fabric layer 140 to the first fabric layer 120 is performed at the same time that the first fabric layer 120 and the second fabric layer 140 are formed on the loom.

FIG. 4 is a schematic illustrating an exemplary method for forming a multilayer fabric 100 according to aspects of the disclosure. A first fabric layer 120 including weft yarns 125 and warp yarns 130 is woven in a 3/1 twill weave pattern (the warp yarn 130 is fed over three of the weft yarns 125 and then under one of the weft yarns 125 in a repeating pattern). A second fabric layer 140 including weft yarns 145 and warp yarns 150 is woven in a 3/1 twill pattern in the same manner. The second fabric layer 140 is tacked 160 to the first fabric layer 120 by feeding one of the weft yarns 125 of the first fabric layer 120—a tacking yarn 165 over the yarns of the second fabric layer 140 as illustrated. In this manner, the second fabric layer 140 is tacked 160 to the first fabric layer 120 at every eighth (8^(th)) weft yarn (pick). Assuming the fabric layers were not also tacked in the warp direction, such a tacking pattern would result in multilayer fabric having longitudinal air pockets (see FIG. 2C).

The first woven fabric layer 120 and the second woven fabric layer 140 of the multilayer fabric 100 may be simultaneously woven on the same loom. While in some aspects multiple warp beams may be used to weave the first woven fabric layer 120 and the second woven fabric layer 140, in a particular aspect the first woven fabric layer 120 and the second woven fabric layer 140 are simultaneously woven using a single warp beam. In certain aspects the first woven fabric layer 120 and the second woven fabric layer 140 are simultaneously woven using double warp beams.

Additional schematics illustrating exemplary methods for forming 2-layer fabrics according to aspects of the disclosure are illustrated in FIGS. 5A-C. FIG. 5A illustrates a 2-layer fabric with a top woven fabric layer 510 in a plain weave pattern, and a bottom woven fabric layer 520 in a 3/1 twill weave pattern. The bottom woven fabric layer 520 is tacked to the top woven fabric layer 510 every 4th yarn/pick.

FIG. 5B illustrates a 2-layer fabric with a top woven fabric layer 530 in a 2/2 twill weave pattern, and a bottom woven fabric layer 540 in a 3/1 twill weave pattern. The bottom woven fabric layer 540 is tacked to the top woven fabric layer 530 every 4^(th) yarn/pick.

FIG. 5C illustrates a 2-layer fabric with a top woven fabric layer 550 in a plain weave pattern, and a bottom woven fabric layer 560 in a 2/2 twill weave pattern. The bottom woven fabric layer 540 is tacked to the top woven fabric layer 530 every 4th yarn/pick.

Additional schematics illustrating exemplary methods for forming multilayer fabrics according to aspects of the disclosure are illustrated in FIGS. 6A and 6B. FIG. 6A illustrates a 3-layer multilayer fabric with a top woven fabric layer 610 in a plain weave pattern, a middle woven fabric layer 620 in a 3/1 twill weave pattern, and a bottom woven fabric layer 630 in a 2/2 twill weave pattern. The bottom woven fabric layer 630 is tacked to the middle woven fabric layer 630 every 6^(th) yarn/pick, and the middle woven fabric layer 620 is tacked to the top woven fabric layer 610 every 4^(th) and 9^(th) a yarn/pick.

FIG. 6B illustrates a 4-layer multilayer fabric with a top woven fabric layer 640 in a plain weave pattern, a second woven fabric layer 650 in a 3/1 twill weave pattern, a third woven fabric layer 660 in a 2/2 twill weave pattern, and a bottom woven fabric layer 670 in a 3/1 twill weave pattern. The bottom woven fabric layer 670 is tacked to the third woven fabric layer 660 every 3^(rd) yarn/pick, the third woven fabric layer 660 is tacked to the second woven fabric layer 650 6^(th) yarn/pick, and the second woven fabric layer 650 is tacked to the top woven fabric layer 640 every 9^(th) yarn/pick.

In accordance with the above, the method may thus in some aspects include weaving more than two fabric layers (e.g., 3, 4, 5, 6, 7 or even 8 fabric layers) on the loom so as to form a multilayer fabric having from 3 to 8, or more than 8, fabric layers.

The multilayer fabric 100 and woven fabric layers formed according to the methods described herein may have any of the functionalities, yarns, yarn types, yarn sizes, yarn colors, fabric constructions, weave types, and optional additional woven fabric layers as described above, and are not repeated herein.

Articles Formed from the Multilayer Fabric

Multilayer fabrics according to aspects described herein and formed according to methods described herein may be useful in a wide range of applications. The multilayer fabrics may be particularly useful in garments as work wear, outerwear, outdoor applications, casual wear, fashion wear, personal protective equipment, and as specialty equipment. In some aspects garments formed from the multilayer fabric include a jacket, pants, jeans, hat, a shirt, an overall, workwear, or active wear.

In particular aspects, garments including the multilayer fabrics described herein could be reversible by incorporating different colors and/or textures in each layer of the multilayer fabric. In one aspect, the front side (layer) of a garment (e.g., denim jeans, workwear pants/shirts) could be have a first color (e.g., blue) and the back side (layer) could include a second color different than the first color so that as the front side (layer) rips the colored back side (layer) is revealed. In yet further aspects the back side/layer of fabric could be multicolored so that each time the front side/layer rips a different color of the back side/layer is exposed. In some aspects workwear fabric could be piece-dyed to achieve multilayer fabrics having the same color (or in further aspects different colors).

In another aspect a garment could include a denim/workwear fabric outer layer and an inner layer including a bi-component fiber such as that described herein. The inner layer will expand when it gets wet as described above, while the outer denim/workwear layer will maintain its aesthetic appearance.

In further aspects a garment could include an outer fabric layer including yarns providing the fabric layer with abrasion resistance, flame resistance and/or water resistance (e.g., yarns including para-aramid and/or meta-aramid fibers), and an inner fabric layer including yarns providing the fabric layer with good softness or hand functionality (e.g., yarns including cotton and/or polyester).

It may be desirable in some aspects to apply a final finishing treatment to only one layer of the multilayer fabric or garment incorporating it. For example, a multilayer fabric including a polyester outer layer and a cotton inner layer could be treated with a durable water repellent (DWR) finish that will only attach to the polyester outer layer and not the cotton inner layer.

In yet further aspects a multilayer stretch fabric could include an outer fabric layer including yarns having one stretch functionality and an inner fabric layer including yarns having another stretch functionality different than the stretch functionality of the outer fabric layer.

Various combinations of elements of this disclosure are encompassed by this disclosure, e.g., combinations of elements from dependent claims that depend upon the same independent claim.

Aspects of the Disclosure

In various aspects, the present disclosure pertains to and includes at least the following aspects.

Aspect 1: A multilayer fabric comprising at least a first woven fabric layer and a second woven fabric layer tacked to the first woven fabric layer, wherein:

the first woven fabric layer provides a first functionality to the multilayer fabric;

the second woven fabric layer provides a second functionality to the multilayer fabric; and

the first functionality is different than the second functionality.

Aspect 2: The multilayer fabric according to Aspect 1, wherein the first functionality and the second functionality are selected from one or more of warming, cooling, all season, flame resistance, antibacterial, odor control, retro-reflectivity, ultraviolet protection, friction resistance, wear resistance, energy resistance, water repellency, water proofing, wind resistance, thermal conductivity, electrical conductivity, stretch, non-stretch, softness, hand, slub, fabric smoothness, yarn size, printability, dyeability, color, color changing, pattern changing, responsivity, energy boosting, skin-moisturizing, infrared (IR) transmitting, IR reflecting, IR absorbing, ventilation, controllable shrinkage, sensing properties, aesthetic look, and aesthetic feel.

Aspect 3: The multilayer fabric according to Aspect 1 or 2, wherein the first woven fabric layer comprises first yarns woven into a first fabric construction, and the first functionality is provided by one or more of the first yarns and the first fabric construction.

Aspect 4: The multilayer fabric according to Aspect 3, wherein the first yarns are woven into the first fabric construction in both a warp direction and a weft direction, and the first yarns woven in the warp direction and the first yarns woven in the weft direction comprise an identical yarn type or a different yarn type.

Aspect 5: The multilayer fabric according to Aspect 4, wherein the first functionality is provided by the first yarns woven in the warp direction, the first yarns woven in the weft direction, or the first yarns woven in both the warp direction and in the weft direction.

Aspect 6: The multilayer fabric according to any of Aspects 1 to 5, wherein the second woven fabric layer comprises second yarns woven into a second fabric construction, and the second functionality is provided by one or more of the second yarns and the second fabric construction.

Aspect 7: The multilayer fabric according to Aspect 6, wherein the second yarns are woven into the second fabric construction in both a warp direction and a weft direction, and the second yarns woven in the warp direction and the second yarns woven in the weft direction comprise an identical yarn type or a different yarn type.

Aspect 8: The multilayer fabric according to Aspect 7, wherein the second functionality is provided by the second yarns woven in the warp direction, the second yarns woven in the weft direction, or the second yarns woven in both the warp direction and in the weft direction.

Aspect 9: The multilayer fabric according to any of Aspects 4 to 8, wherein the first fabric construction comprises a first weave type and the second fabric construction comprises a second weave type and the first weave type and the second weave type are independently selected from a plain weave, a twill weave, a satin weave, a pile weave, a dobby weave, a knit-look weave, a rip-stop, derivatives thereof, and combinations thereof.

Aspect 10: The multilayer fabric according to any of Aspects 6 to 9, wherein the first yarns and the second yarns are independently selected from spun yarns, filament yarns, fancy yarns, bi-component yarns, core sheath hybrid yarns, or a combination thereof.

Aspect 11: The multilayer fabric according to Aspect 10, wherein the spun yarns comprise staple fibers selected from the group consisting of cotton, flax, jute, hemp, ramie, bamboo, pineapple, banana, wool, bean, milk, cashmere, silk, kapok, polyester, nylon, polypropylene, acrylic, rayon, cellulose, acetate, viscose, modal, lyocell, para aramid, meta aramid, polytetrafluoroethylene, FR cotton, FR polyester, FR nylon, polylactic acid (PLA), poly(trimethylene terephthalate) (PTT), polybenzimidazole (PBI), conductive fibers, optical fibers, copolymers thereof, blends thereof, and combinations thereof.

Aspect 12: The multilayer fabric according to Aspect 10 or 11, wherein the filament yarns comprise fibers selected from the group consisting of polyester, nylon, polyethylene, polypropylene, acrylic, cellulose-acetate, viscose, modal, lyocell, meta aramid, para aramid, polytetrafluoroethylene, FR polyester, FR nylon, melamine, modacrylic, elastomeric fibers, polylactic acid (PLA), poly(trimethylene terephthalate) (PTT), polybenzimidazole (PBI), conductive fibers, optical fibers, bi-component filament comprising two of these fibers, multi-component filament comprising three or more of these fibers, copolymers thereof, blends thereof, and combinations thereof.

Aspect 13: The multilayer fabric according to Aspect 10, wherein one or more of the first yarns and the second yarns comprise bi-component yarns, and the bi-component yarns comprise two or more fibers selected from polyester, nylon, cellulose and acetate.

Aspect 14: The multilayer fabric according to any of Aspects 1 to 13, wherein the second woven fabric layer is tacked to the first woven fabric layer in a warp direction, a weft direction, or in both the warp direction and the weft direction.

Aspect 15: The multilayer fabric according to any of Aspects 1 to 14, further comprising air pockets between the second woven fabric layer and the first woven fabric layer resulting from tacking between the second woven fabric layer and the first woven fabric layer.

Aspect 16: The multilayer fabric according to Aspect 15, wherein the air pockets provide thermal insulation to the multilayer fabric.

Aspect 17: The multilayer fabric according to Aspect 15 or 16, wherein the tacking is performed in a tunable pattern such that the air pockets are formed in the multilayer fabric in a tunable pattern with a tunable size.

Aspect 18: The multilayer fabric according to any of Aspects 1 to 17, wherein the first woven fabric layer and the second woven fabric layer are simultaneously woven on the same loom.

Aspect 19: The multilayer fabric according to Aspect 18 wherein the first woven fabric layer and the second woven fabric layer are simultaneously woven using a single warp beam or a multiple warp beam.

Aspect 20: The multilayer fabric according to any of Aspects 1 to 19, wherein the fabric comprises at least a third woven fabric layer tacked to one or both of the first woven fabric layer and the second woven fabric layer.

Aspect 21: The multilayer fabric according to Aspect 20, wherein the third woven fabric layer has a third functionality that is different than one or both of the first functionality and the second functionality.

Aspect 22: A garment formed from the multilayer fabric of any of Aspects 1 to 21.

Aspect 23: The garment according to Aspect 22, wherein the garment comprises a jacket, pants, jeans, hat, a shirt, an overall, workwear, or active wear.

Aspect 24: A method for forming a multilayer fabric, comprising:

weaving a first fabric layer on a loom, the first fabric layer having a first functionality;

weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different than the first functionality; and

tacking the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom.

Aspect 25: The method according to Aspect 24, wherein the loom comprises a single warp beam or a multiple warp beam.

Aspect 26: The method according to Aspect 24 or 25, further comprising:

weaving at least a third fabric layer on the loom, the third fabric layer having a third functionality that is different than one or both of the first functionality and the second functionality; and

tacking the third fabric layer to one or both of the first fabric layer and the second fabric layer.

Aspect 27: The method according to any of Aspects 24 to 26, wherein the multilayer fabric comprises from 2 to 8 woven fabric layers.

EXAMPLES

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and/or methods claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for.

Example 1—Functional 2-Layer Fabric Providing Thermal Functionalities

On the top layer, the warp yarns are cotton with a yarn size 10's (cotton count), the weft yarns are Coolmax® (available from Invista) hollow yarn with a yarn size 14's. The fabric construction is a plain weave with 70*40, which can provide insulation.

On the bottom layer, the warp yarns are acrylic with a yarn size 10's, the weft yarns are wool with a yarn size 14's, the fabric construction is a 3/1 twill weave with 70*40, which can provide warmth.

Example 2—Functional 2-Layer Fabric Providing Abrasion Resistance and Warming

On the top layer, the warp yarns are nylon with a yarn size 400D (filament), the weft yarns are polytetrafluoroethylene (PTFE) with a yarn size 300D, the fabric construction is a 2/1 twill with 60*40, which can provide abrasion resistance.

On the bottom layer, the warp yarns are kapok (natural hollow fiber) with a yarn size 500D, the weft yarns are infrared (IR) reflective polyester with a yarn size 300D (the weft yarns are regular polyester with IR reflective printing such as aluminum printed on the inner side of the bottom layer to provide warmth), the fabric construction is a 3/1 twill with 60*40, which can provide warmth.

Example 3—Functional 2-Layer Fabric Providing Water Repellency and Cooling

On the top layer, both the warp yarns (yarn size 10's) and the weft yarns (yarn size 12's) are cotton treated with a fluorocarbon chemical to provide water repellency, the fabric construction is a broken twill or a rip-stop with 60*40.

On the bottom layer, the warp yarns are polyester 450D with carbon-based particles to provide high thermal conductivity, the weft yarns are polyester 400D with an oval-scalloped shape filament cross-section to provide improved moisture wicking, the fabric construction is a sateen with 60*40, which can provide cooling.

Example 4—Functional 2-Layer Fabric Providing Softness

On the top layer, both the warp yarns (yarn size 500D) and the weft yarns (yarn size 300D) are lyocell, the fabric construction is a 2/1 twill with 65*40, which can provide softness.

On the bottom layer, the warp yarns are micro-denier nylon with a yarn size 450D, the weft yarns are modal with a yarn size 300D, the fabric construction is a satin with 65*40, which can provide softness.

Example 5—Functional 2-Layer Fabric Providing Flame Retardancy

On the top layer, both the warp yarns and the weft yarns are FR-treated cotton with a yarn size 10's, the fabric construction is a 2/2 twill with 70*40, which can provide fire-retardant.

On the bottom layer, both warp and weft yarns are kapok (natural hollow fiber) with a yarn size 10's, the fabric construction is a 3/1 twill with 70*40, which are natural hollow yarns and can provide insulation.

Example 6—2-Layer Fabric Providing Stretch and Aesthetic Functionalities

On the top layer, the warp yarns are cotton/T400 (stretch warp yarn) with a yarn size 500D, the weft yarns are polyester/spandex with a yarn size 300D, the fabric construction is a 2/2 weave with 60*40, which can provide two-way stretch properties.

On the bottom layer, the warp yarns are cotton/T400 in red color with a yarn size 500D, the weft yarns are nylon/spandex in blue color with a yarn size 300D, the fabric construction is a basket weave with 60*40, which can provide two-way stretch and color.

As the top layer stretches, the yarns and color from the bottom layer will become visible. If the top layer is ripped off, the bottom layer with the different fabric construction and color will also become visible, providing a different aesthetic look.

Example 7—2-Layer Smart Textile Providing Optical and Responsive Functionalities

On the top layer, the warp yarns are cotton with a yarn size 10's, the weft yarns are polyester yarn with a yarn size 300D but have an optical fiber/yarn inserted at one pick every inch. The fabric construction is a plain weave with 70*40. With a continuous optical fiber/yarn, and when operated with battery/phone/power bank, the fabric will illuminate or light up, providing a fashion look. The fabric could also be useful for personal protection, such as when wearing a garment made from this fabric in the evening walking in the dark.

On the bottom layer, both the warp 500D and the weft yarns 300D are responsive yarns (such as but not limited to VENTCOOL™ or AeroReact bi-component fibers described herein), which are more open structure when hot & humid but which become more closed when cold & dry. In addition, the thickness of the bottom layer fabric can change—it is thicker when cold and thinner when hot. In this manner, it provides better thermal comfort through thermoregulation.

Example 8—2-Layer Smart Textile Providing Electrically Conductive Functionality

On the top layer, the warp yarns are polyester/viscose with a yarn size 10's, the weft yarns are Coolmax hollow yarn with a yarn size 14's, the fabric construction is a 2/2 twill with 80*40, which can provide insulation and soft hand feel.

On the bottom layer, the warp yarns are poly/wool blends with a yarn size 10's, the weft yarns are polyester having a “star” shape cross-section with a yarn size 14's, which provide better moisture management. The weft yarns also have an electrical conductive fiber/yarn inserted one pick every inch. The fabric construction is a broken twill with 60*40.

With a continuous conductive fiber/yarn, and when operated with battery/phone/power bank, the fabric will provide warmth. The fabric may also be useful in medical applications (as a warming blanket, for example).

Example 9—2-Layer Smart Textile Having a Material Inserted Between the Layers

On the top layer, the warp yarns are cotton with a yarn size 10's, the weft yarns are nylon/spandex yarn with a yarn size 14's, the fabric construction is a 3/1 twill with 70*40.

On the bottom layer, the warp yarns are cotton with a yarn size 10's, the weft yarns are acrylic/spandex with a yarn size 14's, the fabric construction is a 2/2 twill with 70*40.

The two layers are tacked in the weft direction to form longitudinal air pockets. Aerogel is filled in the air pockets. The fabric has low thermal conductivity and high heat retention, which provides superior warmth and insulation.

Example 10—3-Layer Fabric Providing Thermal Functionalities

On the top layer, both the warp yarns (yarn size 10's) and the weft yarns (yarn size 14's) are cotton, the fabric construction is a 3/1 twill with 70*40, which can provide an authentic look.

In the middle layer, the warp yarns are Kapok (natural hollow fiber) with a yarn size 10's, the weft yarns are Coolmax® hollow yarns with a yarn size 14's, the fabric construction is a 3/1 twill with 60*40, which can provide insulation.

On the bottom layer, the warp yarns are acrylic with a yarn size 10's, the weft yarns are staple polyester/wool blends with a yarn size 14's, and the fabric construction is a 2/2 twill weave with 65*40, which can provide superior warmth.

The three layers are tacked every 8 picks in the weft direction.

Example 11—Functional 2-Layer Fabrics Providing Thermal Functionality

Example fabrics were made according to the following specifications.

Example 11A (Ex.11A)

top layer was cotton warp yarns (20/2's spun yarns) and cotton weft yarns (16's spun yarns), fabric construction was 3/1 twill with 64*42; bottom layer was staple polyester warp yarns (266D), staple polyester weft yarns (266D), fabric construction was 3/1 twill with 64*42. The layers were tacked every 8 picks in the weft direction.

Example 11B (Ex.11B)

top layer was cotton warp yarns (20/2's spun yarns) and cotton weft yarns (16's spun yarns), fabric construction was 3/1 twill with 64*42; bottom layer was polyester/wool warp fibers (16's) and poly/wool weft fibers (32's), fabric construction was 3/1 twill with 64*42. The layers were tacked every 8 picks in the weft direction.

Comparative Example 11A (C.11A)

100% cotton woven fabric; warp yarns and weft yarns are cotton spun yarns (yarn size about 8's), fabric construction is 3/1 twill with about 70*40.

Comparative Example 11B (C.11B)

Acrylic/cotton woven fabric; warp yarns are cotton spun yarns (yarn size about 7/8's), weft yarns are acrylic spun yarns and include 40D spandex (yarn size about 12's), fabric construction is 3/1 twill with about 90*50.

Comparative Example 11C (C.11C)

cotton/wool fabric; cotton spun yarns are in the warp yarns, cotton and wool blend spun yarns are in the weft yarns, fabric construction is a 3/1 twill.

Comparative Example 11D (C.11D)

fleece fabric; top layer is 100% cotton; bottom layer is one-sided polyester fleece fabric.

Comparative Example 11E (C.11E)

Invista Thermolite® fabric; cotton warp yarns and Thermolite® weft yarns.

The thermal conductivity (TCC) and contact heat flow (Qmax) of the example and comparative fabrics was measured; results are set forth in Table 1:

TABLE 1 Comparison of Thermal Properties of Fabrics Thickness TCC Qmax Fabric (mm) (W/(m-K/mm)) (W/(m²-K)) Ex. 11A 1.546 47.3 514.9 Ex. 11B 1.672 47.0 521.4 C. 11A 1.107 68.3 1011.1 C. 11B 0.748 86.8 888.3 C. 11C 0.658 84.9 884.6 C. 11D 1.943 32.7 400.4 C. 11E 0.686 88.2 914.0 Thickness is provided in millimeters (mm) TCC is provided in watts per meter-Kelvin per millimeter (W/(m-K/mm)) Qmax is provided in watts per square meter-Kelvin (W/(m²-K))

TCC and Qmax were measured with an FTT Fabric Touch Tester, available from SDL Atlas. As is evident from the data, the inventive dual-layer fabrics (Ex.11A and Ex.11B) each have a much lower thermal conductivity and Qmax than the comparative fabrics, which indicates that they have high warmth. Their warmth is comparable to that of fleece fabric, which includes two layers of fabric sewn together with air in-between. Fleece fabrics, however, are much thicker and heavier than the inventive fabrics, which are not only comparatively lighter, but the multiple layers of the inventive fabrics can be simultaneously made on the same loom as described herein. FIGS. 7A and 7B provide exemplary illustrations of fleece fabrics (FIG. 7A) compared to a multilayer (2-layer) denim fabric according to the disclosure (FIG. 7B).

Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, in an example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

What is claimed is:
 1. A multilayer fabric comprising at least a first woven fabric layer and a second woven fabric layer tacked to the first woven fabric layer, wherein: the first woven fabric layer provides a first functionality to the multilayer fabric; the second woven fabric layer provides a second functionality to the multilayer fabric; and the first functionality is different than the second functionality.
 2. The multilayer fabric according to claim 1, wherein the first functionality and the second functionality are selected from one or more of warming, cooling, all season, flame resistance, antibacterial, odor control, retro-reflectivity, ultraviolet protection, friction resistance, wear resistance, energy resistance, water repellency, water proofing, wind resistance, thermal conductivity, electrical conductivity, stretch, non-stretch, softness, hand, slub, fabric smoothness, yarn size, printability, dyeability, color, color changing, pattern changing, responsivity, energy boosting, skin-moisturizing, infrared (IR) transmitting, IR reflecting, IR absorbing, ventilation, controllable shrinkage, sensing properties, aesthetic look, and aesthetic feel.
 3. The multilayer fabric according to claim 1, wherein the first woven fabric layer comprises first yarns woven into a first fabric construction, and the first functionality is provided by one or more of the first yarns and the first fabric construction.
 4. The multilayer fabric according to claim 3, wherein the first yarns are woven into the first fabric construction in both a warp direction and a weft direction, and the first yarns woven in the warp direction and the first yarns woven in the weft direction comprise an identical yarn type or a different yarn type.
 5. The multilayer fabric according to claim 4, wherein the first functionality is provided by the first yarns woven in the warp direction, the first yarns woven in the weft direction, or the first yarns woven in both the warp direction and in the weft direction.
 6. The multilayer fabric according to claim 1, wherein the second woven fabric layer comprises second yarns woven into a second fabric construction, and the second functionality is provided by one or more of the second yarns and the second fabric construction.
 7. The multilayer fabric according to claim 6, wherein the second yarns are woven into the second fabric construction in both a warp direction and a weft direction, and the second yarns woven in the warp direction and the second yarns woven in the weft direction comprise an identical yarn type or a different yarn type.
 8. The multilayer fabric according to claim 7, wherein the second functionality is provided by the second yarns woven in the warp direction, the second yarns woven in the weft direction, or the second yarns woven in both the warp direction and in the weft direction.
 9. The multilayer fabric according to 6, wherein the first fabric construction comprises a first weave type and the second fabric construction comprises a second weave type and the first weave type and the second weave type are independently selected from a plain weave, a twill weave, a satin weave, a pile weave, a dobby weave, a knit-look weave, a rip-stop, derivatives thereof, and combinations thereof.
 10. The multilayer fabric according to claim 1, wherein the second woven fabric layer is tacked to the first woven fabric layer in a warp direction, a weft direction, or in both the warp direction and the weft direction.
 11. The multilayer fabric according to claim 1, further comprising air pockets between the second woven fabric layer and the first woven fabric layer resulting from tacking between the second woven fabric layer and the first woven fabric layer.
 12. The multilayer fabric according to claim 11, wherein the tacking is performed in a tunable pattern such that the air pockets are formed in the multilayer fabric in a tunable pattern with a tunable size.
 13. The multilayer fabric according to claim 1, wherein the first woven fabric layer and the second woven fabric layer are simultaneously woven on the same loom.
 14. The multilayer fabric according to claim 13 wherein the first woven fabric layer and the second woven fabric layer are simultaneously woven using a single warp beam or a multiple warp beam.
 15. A garment formed from the multilayer fabric of claim
 1. 16. The garment according to claim 15, wherein the garment comprises a jacket, pants, jeans, hat, a shirt, an overall, workwear, or active wear.
 17. A method for forming a multilayer fabric, comprising: weaving a first fabric layer on a loom, the first fabric layer having a first functionality; weaving at least a second fabric layer on the loom, the second fabric layer having a second functionality different than the first functionality; and tacking the second fabric layer to the first fabric layer while the first fabric layer and the second fabric layer are on the loom.
 18. The method according to claim 17, wherein the loom comprises a single warp beam or a multiple warp beam.
 19. The method according to claim 17, further comprising: weaving at least a third fabric layer on the loom, the third fabric layer having a third functionality that is different than one or both of the first functionality and the second functionality; and tacking the third fabric layer to one or both of the first fabric layer and the second fabric layer.
 20. The method according to claim 17, wherein the multilayer fabric comprises from 2 to 8 woven fabric layers. 